risk assessment report -...

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RISK ASSESSMENT REPORTFOR

“PROPOSED EXPANSION OF ACTIVEPHARMACEUTICAL INGRADIENTS AND

CHEMICAL INTERMEDIATES”

BY

M/s. Wohler Laboratories Pvt. Ltd

ATKIADB INDUSTRIAL AREA

VILLAGE : KOLHAR & NIZAMPURTALUK : BIDAR

DISTRICT : BIDARSTATE : KARNATAKA

REPORT PREPARED BY

(NABET Accredited vide Certificate No. NABET/EIA/1618/SA0015 &MoEF Recognized Lab vide F. No. Q-15018/29/2007-CPW)HUBERT ENVIRO CARE SYSTEMS (P) LTD, CHENNAI

APRIL 2017

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BY





REPORT PREPARED BY


APRIL 2017

1




BY





REPORT PREPARED BY


APRIL 2017

2

TABLE OF CONTENTS

1 INTRODUCTION ................................................................................................................................5

1.1 Purpose of the report .....................................................................................................................5

1.2 Scope of the study .........................................................................................................................5

1.3 Methodology adopted ...................................................................................................................6

2 RISK ASSESSMENT METHODOLOGY ...........................................................................................8

2.1 Identification of Hazards & release scenarios...............................................................................8

2.1.4 Factors considered for identification of hazards ................................................................... 9

3 CONSEQUENCE ANALYSIS...........................................................................................................16

3.1 Scenarios possible .......................................................................................................................16

3.2 Weather probabilities ..................................................................................................................16

3.2.1 Wind velocity & stability class ...........................................................................................16

3.2.2 Weather input......................................................................................................................17

3.3 Accident scenarios for this project..............................................................................................17

3.3.1 Consequence analysis for Storage tank...............................................................................17

3.4 Summary of results and observations .........................................................................................38

4 MITIGATIVE MEASURES...............................................................................................................39

4.1 Summary of risk analysis and findings .......................................................................................39

4.2 Recommendations for improving safety .....................................................................................39

5 EMERGENCY PLAN ........................................................................................................................40

5.1 Objectives ...................................................................................................................................40

5.2 Basic forms of Emergency ..........................................................................................................40

5.3 Types of Emergency ...................................................................................................................40

5.4 Causes of Emergency..................................................................................................................41

5.5 Safety, Health & Environment Policy.........................................................................................41

5.6 Mitigation Measures Required....................................................................................................42

5.7 Emergency Shutting Down Procedure ........................................................................................42

5.8 Control Room..............................................................................................................................43

5.9 Alert Action Plan during Working &Non Working Hours .........................................................43

5.10 On Site Emergency Planning ......................................................................................................45

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5.11 Offsite Emergency Plan ..............................................................................................................52

5.11.1 Preamble .................................................................................................................................52

5.11.2 Objective .................................................................................................................................52

5.11.3 Offsite Emergency Control .....................................................................................................52

5.11.4 Emergency Instruction to the General Public .........................................................................53

5.11.5 Category of Alarm Systems ....................................................................................................53

5.11.6 Fire Fighting System ...............................................................................................................54

5.11.7 General Instruction to the Public.............................................................................................54

5.11.8 Security & Police ....................................................................................................................55

LIST OF TABLES

Table 2.1 Chemical properties and classification .......................................................................................10Table 2.2 Damages to Human Life Due to Heat Radiation ........................................................................13Table 2.3 Effects Due To Incident Radiation Intensity...............................................................................13Table 2.4 Effects Due To peak overpressure ..............................................................................................14Table 3.1 Pasquill – Giffard Atmospheric Stability....................................................................................16Table 3.2 Atmospheric data (Manual Input for the worst scenario) ...........................................................17Table 3.3 Input details of Storage tank .......................................................................................................17Table 3.4 Consequence analysis for Storage Tanks....................................................................................18Table 3-5 Estimated distance due to Catastrophic Rupture of Storage tank ...............................................26Table 3-6 Storage tank pipeline details.......................................................................................................33Table 3-7: Estimated distance due to failure of Storage tank pipeline........................................................33

LIST OF FIGURES

Figure 1-1 Plant Layout ................................................................................................................................6Figure 3-1 Dispersion of vapor cloud from Leak of Methanol storage tank...............................................21Figure 3-2 Jet Fire from Leak of Methanol storage tank ............................................................................22Figure 3-3 Pool fire from Leak of Methanol storage tank ..........................................................................23Figure 3-4 Flash Fire from Leak of Methanol storage tank ........................................................................24Figure 3-5 Dispersion of vapor cloud from Leak of n-Propanol Storage tank ...........................................25Figure 3-6 Toxic area of vapor cloud from rupture of Methanol Storage tank...........................................28Figure 3-7 Late Pool fire from rupture of Methanol Storage tank ..............................................................29Figure 3-8 Flash fire from rupture of Methanol Storage tank.....................................................................30Figure 3-9 Toxic area of vapor cloud from rupture of n-Propanol Storage tank ........................................31Figure 3-10 Pool fire from rupture of n-Propanol Storage tank..................................................................32Figure 3-11 Toxic area of vapor cloud from rupture of Methanol Storage tank pipeline ...........................34Figure 3-12 Jet fire from rupture of Methanol Storage tank pipeline .........................................................35

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Figure 3-13 Pool fire from rupture of Methanol Storage tank pipeline ......................................................36Figure 3-14 Flash fire from rupture of Methanol Storage tank pipeline .....................................................37

ABBREVIATIONS

KIADB Karnataka Industrial Areas Development Board

ALARP As Low As Reasonably Practical

TNO Thai National Observatory

NFPA National Fire Protection Association

LFL Lower Flammability Limit

AAQ Ambient Air Quality

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1 INTRODUCTION

1.1 Purpose of the report

The purpose of the study is to identify and assess those hazards and risks arising from

“Proposed Expansion of Active Pharmaceutical Ingredients and Chemical Intermediates” at

Plot no: 123, 124 & 142, Kolhar Village, Bidar Tehsil, Bidar District, Karnataka State.

Based on the available studies & plant layout, the potential scenarios which can cause

significant consequences like fire and explosion scenarios were identified.

The purpose of the study includes the following:

To identify and assess those hazards and risks with NFPA rating.

To eliminate or reduce to As Low As Reasonably Practical (ALARP) in terms of risk to

human health, risk of injury, risk of damage to plant, equipment and environment,

business interruption or loss etc.,

To Suggest On-site and Off-site mitigative Measures.

1.2 Scope of the study

Hazard Identification and Risk Analysis including identification, screening of scenarios,

consequence analysis of the various risk scenarios, recommendation and preparation of

reports and relevant drawing showing damage and risk contours.

The scope of the study mainly involves:

Identifications of Hazards

Consequence modeling

Vapour Cloud

Jet Fire

Pool fire

Flash fire

Impact limits identifications

Contour mapping of the risk on the layouts.

Mitigating measures for handling and storage to reduce impacts & prevent incidents.

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1.3 Methodology adopted

The Risk Assessment has been carried out by using the ALOHA software 5.4.5 (Aerial

Locations of Hazardous Atmospheres) which was developed by office of Emergency

management, EPA and Emergency Response Division, NOAA & PHAST Lite 7.11 (Licence

number 1603-120331(S-28502)) developed by DNV GL AS 2014.

1.4 Basic Facilities details

The plant layout is shown below

Figure 1-1 Plant Layout

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1.5 Storage tank details

1.6 Pipeline details

S.No Dia (m)

Height(m)

Volume(m3)

InternalTemperature(oC)

InternalPressure(bar)

Solvent/Chemicals Names

Type ofstorage tank

1. 2 6 20 Atmospheric Atmospheric Methanol Above ground

2. 2.1 6 20 Atmospheric Atmospheric n-Propanol Above ground

3. 3 6 20 Atmospheric Atmospheric Sulfuric Acid Above ground

4. 2 6.3 20 Atmospheric Atmospheric Hcl Above ground

S. No PipeNo./Name

PipelineSize dia

(m)

Pipelinelength (m)

OperatingTemperature

(oC)

OperatingPressure

(bar)

Chemicalflowing

1. 1 Methanol 0.051 5 35 1 Methanol

2. n-Propanol 0.038 6 30 1 n-propanol

3. SulfuricAcid

0.051 3 25 1 Sulfuric Acid

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2 RISK ASSESSMENT METHODOLOGY

2.1 Identification of Hazards & release scenarios

A technique commonly used to generate an incident list is to consider potential leaks,

ruptures and fractures of all process pipelines and vessels/tanks. The following data were

collected to envisage scenarios:

Solvent Tank conditions (phase, temperature, pressure) and dimensions.

Pipelines connected from storage tanks to reaction process

2.1.1 Selection

The goal of selection is to limit the total number of incident outcome cases to be studied

to a manageable size. The purpose of incident outcome selection is to develop a set of

incident outcomes that must be studied for each incident included in the finalized incident

study list. Each incident needs to be considered separately. Using the list of incident

outcomes the risk analyst needs to determine which may result from each incident. While

the analyst can decide whether an incident involving the loss of a process chemical to the

atmosphere needs to be examined using dispersion analysis because of potential toxic gas

effects, what happens if the same material is immediately ignited on release.

2.1.2 Characterising the Failures

Accidental release of flammable or toxic vapors can result in severe consequences.

Delayed ignition of flammable vapors can result in blast overpressures covering large

areas. This may lead to extensive loss of life and property. Toxic clouds may cover yet

larger distances due to the lower threshold values in relation to those in case of explosive

clouds (the lower explosive limits). In contrast, fires have localized consequences. Fires

can be put out or contained in most cases; there are few mitigating actions one can take

once a vapor cloud gets released. Major accident hazards arise, therefore, consequent

upon the release of flammable or toxic vapors or BLEVE in case of pressurized liquefied

gases. In an industry, main hazard arises due to storage and handling of hazardous

chemicals. To formulate a structured approach to identification of hazards and

understanding of contributory factors is essential.

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2.1.3 Inventory

Inventory Analysis is commonly used in understanding the relative hazards and short

listing of release scenarios. Inventory plays an important role in regard to the potential

hazard. Larger the inventory of a vessel or a system, larger the quantity of potential

release. A practice commonly used to generate an incident list is to consider potential

leaks and major releases from fractures of pipelines and vessels containing sizable

inventories. The potential vapor release (source strength) depends upon the quantity of

liquid release, the properties of the materials and the operating conditions (pressure,

temperature). If all these influencing parameters are combined into a matrix and vapor

source strength computed for each release case, a ranking should become a credible

exercise.

Loss of Containment

Liquid Release may be instantaneous. Failure of a vessel leading to an instantaneous

outflow assumes the sudden appearance of such a major crack that practically all of the

contents above the crack shall be released in a very short time.

The more likely event is the case of liquid release from a hole in a pipe connected to the

vessel. The flow rate will depend on the size of the hole as well as on the pressure in front

of the hole, prior to the accident. Such pressure is basically dependent on the pressure in

the vessel.

The vaporization of released liquid depends on the vapor pressure and weather

conditions. Such consideration and others have been kept in mind both during the initial

listing as well as during the short listing procedure. Initial listing of all significant

inventories in the process plants was carried out. This ensured no omission through in

advertence.

2.1.4 Factors considered for identification of hazards

In any installation, main hazard arises due to loss of containment during handling of

flammable and toxic chemicals. The Chemicals are classified according to the properties and

hazard class given by National Fire Protection Association (NFPA) is responsible for 380

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codes and standards that are designed to minimize the risk and effects of fire by establishing

criteria for building, processing, design, service and installation.

NFPA classification for Health, Flammability & Reactivity of a chemical is on a scale from

0-4 least to worst. As per the NFPA Rating on the scale from 0-4 the chemicals having 3 &

4 are considered are highly hazardous and considered for analysis.

Health Fire

0-No hazard 0-will not burn

1-can cause significant irritation 1- must be preheated before ignition occur

2-can cause temporary incapacitation or

residual injury

2-must be heated or high ambient temperature

to burn

3-can cause serious or permanent injury 3- can be ignited under almost all ambient

4-can be lethal 4-will vaporize and readily burn at normal

temp

The proposed chemicals list are mentioned in Table 2.1

Table 2.1 Chemical properties and classification

S.No Tank

Name

Hazardous

material

Application Boiling

Point

(°C)

NFPA Rating Physical

StateFire Health Reactivity

1 MS Tank MethanolSolvent 64.7 3 1 0 Liquid

2 MS Tank PropanolSolvent 97 3 1 0 Liquid

3 PP FRP HClSolvent 110 0 3 1 Liquid

4 MS Tank Sulfuric acidSolvent 337 0 3 2 Liquid

The fire hazard is considered for Methanol and Propanol except HCl and Sulfuric acid in

which the fire hazard is minimum. The health hazard is observed in HCl and Sulfuric acid.

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2.2 TYPES OF OUTCOME EVENTS

In this section of the report we describe the probabilities associated with the sequence of

occurrences which must take place for the incident scenarios to produce hazardous effects

and the modelling of their effects.

Considering the present case the outcomes expected are

- Jet fire

- Flash Fire

- Vapour Cloud

- Pool Fire

JET FIRE

Jet fire occurs when a pressurized release (of a flammable gas or vapour) is ignited by any

source. They tend to be localized in effect and are mainly of concern in establishing the

potential for domino effects and employee safety zones rather than for community risks.

The jet fire model is based on the radiant fraction of total combustion energy, which is

assumed to arise from a point slowly along the jet flame path. The jet dispersion model

gives the jet flame length.

FLASH FIRE

A flash fire is the non-explosive combustion of a vapour cloud resulting from a release of

flammable material into the open air, which after mixing with air, ignites. A flash fire results

from the ignition of a released flammable cloud in which there is essentially no increase in

combustion rate. The ignition source could be electric spark, a hot surface, and friction

between moving parts of a machine or an open fire. Part of the reason for flash fires is that,

flammable fuels have a vapour temperature, which is less than the ambient Temperature.

Hence, as a result of a spill, they are dispersed initially by the negative buoyancy of cold

vapours and subsequently by the atmospheric turbulence. After the release and dispersion of

the flammable fuel the resulting vapour cloud is ignited and when the fuel vapour is not

mixed with sufficient air prior to ignition, it results in diffusion fire burning. Therefore the

rate at which the fuel vapour and air are mixed together during combustion determines the

rate of burning in the flash fire.

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The main dangers of flash fires are radiation and direct flame contact. The size of the

flammable cloud determines the area of possible direct flame contact effects. Radiation

effects on a target depend on several factors including its distance from the flames, flame

height, flame emissive power, local atmospheric transitivity and cloud size.

VAPOUR CLOUD

Vapour cloud is the result of flammable materials in the atmosphere, a subsequent

dispersion phase, and after some delay an ignition of the vapour cloud. Turbulence is the

governing factor in blast generation, which could intensify combustion to the level that will

result in an explosion. Obstacles in the path of vapour cloud or when the cloud finds a

confined area, as under the bullets, often create turbulence. Insignificant level of

confinement will result in a flash fire. The Vapour cloud will result in overpressures.

It may be noted that Vapour cloud has been responsible for very serious accidents involving

severe property damage and loss of lives.

POOL FIRE

This represents a situation when flammable liquid spillage forms a pool over a liquid or

solid surface and gets ignited. Flammable liquids can be involved in pool fires where they

are stored and transported in bulk quantities. Early pool fire was caused when the steady

state is reached between the outflow of flammable material from the container and complete

combustion of the flammable material when the ignition source is available. Late pool fires

are associated with the difference between the release of material and the complete

combustion of the material simultaneously. Late pool fires are common when large quantity

of flammable material is released within short time.

2.3 Heat Radiation

The effect of fire on a human being is in the form of burns. There are three categories of

burn such as first degree, second degree and third degree burns. The consequences caused

by exposure to heat radiation are a function of:

The radiation energy onto the human body [kW/m2];

The exposure duration [sec];

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The protection of the skin tissue (clothed or naked body).

The limits for 1% of the exposed people to be killed due to heat radiation, and for second-

degree burns are given in the Table below:

Table 2.2 Damages to Human Life Due to Heat Radiation

Exposure Duration Radiation energy

(1% lethality,

kW/m2)

Radiation energy for

2nd degree burns,

kW/m2

Radiation energy for

first degree burns,

kW/m2

10 sec 21.2 16 12.5

30 sec 9.3 7 4

Table 2.3 Effects Due To Incident Radiation Intensity

INCIDENT RADIATION

(kW/m2)

TYPE OF DAMAGE

0.7 Equivalent to Solar Radiation

1.6 No discomfort for long exposure

4.0 Sufficient to cause pain within 20 sec. Blistering of skin (first

degree burns are likely)

9.5 Pain threshold reached after 8 sec. second degree burns after

20 sec.

12.5 Minimum energy required for piloted ignition of wood,

melting plastic tubing’s etc.

37.5 Heavy Damage to process equipment

TYPE OF DAMAGE

The actual results would be less severe due to the various assumptions made in the models

arising out of the flame geometry, emissivity, angle of incidence, view factor and others. The

radioactive output of the flame would be dependent upon the fire size, extent of mixing with air

and the flame temperature. Some fraction of the radiation is absorbed by carbon dioxide and

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water vapour in the intervening atmosphere. Finally the incident flux at an observer location

would depend upon the radiation view factor, which is a function of the distance from the flame

surface, the observer’s orientation and the flame geometry.

Assumptions made for the study (As per the guidelines of CPR 18 E Purple Book)

The lethality of a jet fire is assumed to be 100% for the people who are caught in the flame.

Outside the flame area, the lethality depends on the heat radiation distances.

For the flash fires lethality is taken as 100% for all the people caught outdoors and for 10%

who are indoors within the flammable cloud. No fatality has been assumed outside the flash

fire area.

Explosion

In case of vapour cloud explosion, two physical effects may occur:

A flash fire over the whole length of the explosive gas cloud;

A blast wave, with typical peak overpressures circular around ignition source.

For the blast wave, the lethality criterion is based on:

A peak overpressure of 0.1bar will cause serious damage to 10% of the housing/structures.

Falling fragments will kill one of each eight persons in the destroyed buildings.

The following damage criteria (Table 2.4) may be distinguished with respect to the peak

overpressures resulting from a blast wave:

Table 2.4 Effects Due To peak overpressure

Peak Overpressure Damage Type Description

0.30 bar Heavy Damage Major damage to plant equipment

structure

0.10 bar Moderate Damage Repairable damage to plant

equipment & structure

0.03 bar Significant Damage Shattering of glass

0.01 bar Minor Damage Crack in glass

Assumptions for the study (As per the guidelines of CPR 18 E Purple Book)

Overpressure more than 0.3 bar corresponds approximately with 50% lethality.

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An overpressure above 0.2 bar would result in 10% fatalities.

An overpressure less than 0.1 bar would not cause any fatalities to the public.

100% lethality is assumed for all people who are present within the cloud proper.

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3 CONSEQUENCE ANALYSIS

3.1 Scenarios possible

As large number of failure cases can lead to the same type of consequences, representative

failure cases are selected for this analysis. The failure cases are based on conservative

assumptions. Typically, failure models considered 100% catastrophic rupture of tanks. The

scenarios are discussed one at a time.

3.2 Weather probabilities

3.2.1 Wind velocity & stability class

As per CPR 18E there are 6 representative weather classes:

Table 3.1 Pasquill – Giffard Atmospheric Stability

S.No. Stability Class Weather Conditions

1 A Very unstable - Sunny, light wind

2 A/B Unstable - as with A only less sunny or more windy

3 B Unstable - as with A/B only less sunny or more windy

4 B/C Moderately unstable – moderate sunny and moderate wind

5 C Moderately unstable – very windy / sunny or overcast / light wind

6 C/D Moderate unstable – moderate sun and high wind

7 D Neutral – little sun and high wind or overcast / windy night

8 E Moderately stable – less overcast and less windy night

9 F Stable – night with moderate clouds and light / moderate wind

10 G Very stable – possibly fog

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3.2.2 Weather input

Table 3.2 Atmospheric data (Manual Input for the worst scenario)

Weather Conditions Moderate Worst Case

Average Wind speed (m/s) 1.5 5

Stability Class D and F D

Wind Direction South West to North East

Temp (Celsius) 44

Humidity (%) 66

Source IMD

3.3 Accident scenarios for this project

3.3.1 Consequence analysis for Storage tank

Table 3.3 Input details of Storage tank

S.No Tank

Name

Chemicals No. of

Tanks

Dia

(m)

Length

(m)

Volume

(m3)

Internal

Temp

(0C)

Leak

hole dia

(m)

Type of

storage

tank

1 MSTank

Methanol 3 2 6 20 35 0.01 AboveGround

2 MSTank

n-Propanol 2 2.1 6 20 35 0.01 AboveGround

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Table 3.4 Consequence analysis for Storage Tanks

S.No Description Event Impact criteria Consequence Distance (m)

Category1.5/F

Category5/D

Category1.5/D

1 Leak of Methanol Storagetank

Dispersion of vaporcloud (VCE)

36500 ppm 14.85 5.68 23.37

73000 ppm 23.29 Nil 12.82

Jet Fire 4 kW/m2 10.47 8.49 10.48

12.5 kW/m2 Nil 7.83 Nil

Pool fire 4 kW/m2 13.06 13.99 13.12

12.5 kW/m2 7.98 9.09 8.04

Flash Fire 36500 ppm 23.29 8.91 23.36

73000 ppm 14.85 4.28 12.82

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S.No Scenarios Event Impact Concentration Distance covered by Storage Tank (m) Effects

Category

1.5/F

Category

5/D

Category

1.5/D

2 Leak of

n-Propanol

Storage

tank

Vapor cloud Red (High) 4000 ppm 11 <10 <10 ERPG-3 (Emergency Response

Planning Guidelines)- The maximum

airborne concentration below which it

is believed nearly all individuals could

be exposed for up to one hour without

experiencing or developing life-

threatening health effects.

Orange

(Medium)

670 ppm 36 <10 29 ERPG-2 The maximum airborne

concentration below which it is

believed nearly all individuals could


experiencing or developing

irreversible or other serious health

effects or symptoms that could impair

an individual’s ability to take

protective action.

Yellow

(Low)

250 ppm 66 24 55 ERPG-1 The maximum airborne

concentration below which it is

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believed nearly all individuals could


experiencing other than mild transient

adverse health effects or perceiving a

clearly defined objectionable odor.

Flammable

area of

Vapor

Cloud

Red 12600 ppm <10 <10 <10 60% LEL = Flame Pockets

Yellow 2100 ppm 19 <10 13 10% LEL

Pool Fire Red (High) 10 Kw/(sq.m) <10 <10 <10 Potentially Lethal within 60sec

Orange

(Medium)

5 Kw/(sq.m) <10 <10 <10 2nd degree burns within 60sec

Yellow

(Low)

2 Kw/(sq.m) <10 <10 <10 Pain within 60sec

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CONTOUR MAPS

Scenario -1: Leak of Methanol storage tank

Case- 1 Dispersion of vapor cloud

Figure 3-1 Dispersion of vapor cloud from Leak of Methanol storage tank

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Case- 2 Jet Fire

Figure 3-2 Jet Fire from Leak of Methanol storage tank

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Case- 3 Pool fire

Figure 3-3 Pool fire from Leak of Methanol storage tank

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Case- 4 Flash Fire

Figure 3-4 Flash Fire from Leak of Methanol storage tank

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Scenario-2 Leak of n-Propanol storage tank (Category 1.5/F)

Case -1 Vapor Cloud

Figure 3-5 Dispersion of vapor cloud from Leak of n-Propanol Storage tank

26

Table 3-5 Estimated distance due to Catastrophic Rupture of Storage tank

S.No Description Event Impactcriteria

Consequence Distance (m)

Category 1.5/F Category 5/D Category 1.5/D

3 Catastrophic ruptureof Methanol Storagetank

Vapor cloud 36500 ppm 105.92 30.54 54.23

73000 ppm Nil 24.31 40.64

Late Pool fire 4 kW/m2 89.78 93.34 89.35

12.5 kW/m2 56.44 65.21 56.04

37.5 kW/m2 36.68 37.15 36.37

Flash fire 36500 ppm 123.70 59.43 70.99

73000 ppm 36.93 30.25 41.13

S.No Scenarios Event Impact Concentration Distance covered by Storage Tank

(m)

Effects

Category

1.5/F

Category

5/D

Category

1.5/D

4 Catastrophic

rupture of

n-Propanol

Storage tank

Vapor cloud Red (High) 4000 ppm 27 10 21 ERPG-3 (Emergency ResponsePlanning Guidelines)- Themaximum airborne concentrationbelow which it is believed nearlyall individuals could be exposed forup to one hour withoutexperiencing or developing life-

27

threatening health effects.Orange

(Medium)

670 ppm 78 29 66 ERPG-2 The maximum airborneconcentration below which it isbelieved nearly all individualscould be exposed for up to one hourwithout experiencing or developingirreversible or other serious healtheffects or symptoms that couldimpair an individual’s ability totake protective action.

Yellow

(Low)

250 ppm 145 74 123 ERPG-1 The maximum airborneconcentration below which it isbelieved nearly all individualscould be exposed for up to one hourwithout experiencing other thanmild transient adverse health effectsor perceiving a clearly definedobjectionable odor.

Flammable

area of

Vapor

Cloud

Red 12600 ppm <10 <10 <10 60% LEL = Flame Pockets

Yellow 2100 ppm 40 19 32 10% LEL

Pool Fire Red (High) 10 Kw/(sq.m) 18 25 18 Potentially Lethal within 60sec

Orange

(Medium)

5 Kw/(sq.m) 26 31 26 2nd degree burns within 60sec

Yellow

(Low)

2 Kw/(sq.m) 41 43 41 Pain within 60sec

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Scenario – 3: Catastrophic rupture of Methanol storage tank

Case-1 Vapor cloud

Figure 3-6 Toxic area of vapor cloud from rupture of Methanol Storage tank

29

Case-2 Late Pool fire

Figure 3-7 Late Pool fire from rupture of Methanol Storage tank

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Case-3 Flash fire

Figure 3-8 Flash fire from rupture of Methanol Storage tank

31

Scenario-4 Catastrophic rupture of n-Propanol Storage tank

Case -1 Vapor cloud

Figure 3-9 Toxic area of vapor cloud from rupture of n-Propanol Storage tank

32

Case -2 Thermal radiation from pool fire

Figure 3-10 Pool fire from rupture of n-Propanol Storage tank

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Table 3-6 Storage tank pipeline details

Table 3-7: Estimated distance due to failure of Storage tank pipeline

S.No Description Event Impact criteria Consequence Distance (m)

Category

1.5/F

Category

5/D

Category

1.5/D

5 Rupture of Methanol Storage tank

pipeline

Dispersion of vapor

cloud (VCE)

36500 ppm 45.98 17.22 36.96

73000 ppm 28.42 9.75 23.50

360000 ppm 7.11 2.69 5.39

Jet Fire 4 kW/m2 21.53 17.99 21.66

12.5 kW/m2 Nil 15.15 Nil

Pool fire 4 kW/m2 40.33 42.17 40.31

12.5 kW/m2 24.91 29.60 24.91

37.5 kW/m2 17.17 17.16 17.17

Flash Fire 36500 ppm 45.98 17.78 36.96

73000 ppm 28.42 10.18 23.50

S.No Pipe No./Name Pipeline Sizedia (m)

Pipeline length(m)

OperatingTemperature (oC)

OperatingPressure( Kg/cm2)

Chemicalflowing

5 Methanol 0.051 5 35 1 Methanol

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Scenario-5 Rupture of Methanol storage tank pipeline

Case-1 Dispersion of vapor cloud

Figure 3-11 Toxic area of vapor cloud from rupture of Methanol Storage tank pipeline

35

Case-2 Jet fire for Methanol tank pipeline

Figure 3-12 Jet fire from rupture of Methanol Storage tank pipeline

36

Case-3 Pool fire for Methanol tank pipeline

Figure 3-13 Pool fire from rupture of Methanol Storage tank pipeline

37

Case- 4 Flash fire for Methanol tank pipeline

Figure 3-14 Flash fire from rupture of Methanol Storage tank pipeline

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3.4 Summary of results and observations

The Consequence analysis study is carried out for the storage tanks and found no impacts

on neighbouring villages.

As per the NFPA rating the solvents such as Methanol and N-Propanol exhibits fire

hazard.

The Consequence analysis study is carried out for Methanol and N-Propanol storage

tanks and found the all the impacts are within plant boundary.

The consequence analysis is carried out for the Methanol storage tank pipeline and found

that the impact is within the plant premises.

All the hazards are observed in North-East direction due to the wind is blowing from

South-West direction.

Mitigative measures for tanks and pipelines are proposed to avoid hazards.

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4 MITIGATIVE MEASURES

4.1 Summary of risk analysis and findings

1. All statutory appurtenances requirement with reference to safety and fire protection havebeen incorporated in the design.

2. Necessary preventive and protective measures are proposed for storage tanks andhandling.

4.2 Recommendations for improving safetyThe following measures are considered for enhancing the safety standards at site:-

1. Operator training and retraining should be a continuous effort and Mock Drills should be

carried out regularly on identified scenarios.

2. Work Permit System should be strictly enforced and should not be allowed to becircumvented.

3. Hoses should be inspected and tested every six monthly for the recommended test pressure.

4. Static protection and integrity of explosion proof equipment should be ensured through regularinspection. Every electrical equipment and lighting features should meet explosion proofrequirement, in classified area.

5. Smoking and carrying smoking material are to be strictly prohibited.

6. Interlock to be provided in the storage tank.

7. Earth link may be connected to pump circuit to ensure startup only after providing tank earth -connection.

8. Safety Procedures and Do’s and Don’ts should be prepared and displayed in handling andstorage area.

9. Conveyor sides should have plastic guide strips in preference to metallic strips to preventfriction and consequent hazards.

10. Periodic inspection of Pipelines and painting to be done to avoid corrosion and subsequentleak.

11. The Plant commissioning has an important role to ensure long term safety. Proper cleaningand flushing of the system should be ensured in storage area and fire hydrant system to avoidpossible hold up of welding slag’s, bolts, nuts etc. which could hamper smooth operation.

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5 EMERGENCY PLAN

5.1 Objectives

a. To establish a method of systematic, safe and orderly evacuation in the least

possible time, to a safe area or by the nearest safe means of way out.

b. Control the accidents.

c. Rapid control and containment of hazardous situation.

d. Rescue and treatment of casualties.

e. Safeguard people (both at site and neighbourhood).

f. Minimize damage to property and environment.

g. Identify casualties, notify their relatives and render necessary help to them.

h. Proper training of the concerned person.

i. Prevent recurrence.

j. Be capable of dealing with largest incident that can reasonably be foreseen.

k. Have sufficient flexibility with a view to handling the emergency efficiently and

avoiding unnecessary calling outside agencies like external fire brigade.

5.2 Basic forms of Emergency

a. Fire

b. Explosion

c. Toxic release

d. Natural disaster (earth quake, flooding, tsunami etc.)

e. A combination of more than one

5.3 Types of Emergency

5.3.1 On-site Emergency

If an accident/ incident takes place in a factory, its effects are confined to the factory

premises, involving only the persons working in the factory and the property inside the

factory it is called as On-site Emergency.

It can be again classified as minor and major emergency based on severity of the incident.

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Minor Emergency (Evacuation is not required)

In the case of minor emergency there will be no evacuation siren and the respective

department personnel will handle the same with assistance of Safety Squad.

Major Emergency (Evacuation is required)

In case of major emergency there will be emergency siren and situation is tackled as per

the plan.

5.3.2 Off-site Emergency

If the accident is such that it affects inside the factory are uncontrollable and it may

spread outside the factory premises, it is called as Off-site Emergency.

Assessment reveals that an Off-site emergency is a very remote possibility in our factory.

If there is a situation, first we shall avail the service of local police to warn and advice the

local public about things to do to save them from the effect of emergency situation.

Moreover, the factory is located in industrial area. Hence, there are no residential houses

in factory surrounding area.

5.4 Causes of Emergency

The emergency may caused by factors like failure of system, human error, sabotage and

natural calamities like earth quake, flooding etc.

Irrespective of cause, the emergency will generally manifest itself in one of the three

basic forms i.e. fire, explosion and release of toxic substance.

5.5 Safety, Health & Environment Policy

1. Assurance of Safety, Protection of Health & Environment is prime function and

responsibility of the Management and the Management will inculcate the safety

behaviour down the line through exemplary behaviour.

2. All the employees are periodically trained & informed about the hazards to which

they are exposed & Safety measures to be taken including personal protective

equipment.

3. To provide the resources required for Safety, Health and Environment protection.

4. We affirm to reduce the wastages, recycle the resources and disposal of wastages

will be as per statutory norms.

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5. All our facilities will be operated & maintained by the prescribed Standard

Operating Procedures covering routine & non-routine activities.

6. All the accidents / near-miss accidents will be investigated thoroughly for their

root cause to avoid recurrence. Corrective and preventive actions applicable for

the same will be enforced.

7. Health, Safety & Environmental performance is constantly measured through

periodic audits of facility for continuous improvements.

5.6 Mitigation Measures Required

a. Fire Hydrant System

b. Fire Extinguisher

c. Emergency Equipments / PPEs

d. Eye Wash Fountain and Safety Shower

e. Work Zone Monitoring Equipments

f. Wind Sack / Wind Direction Indicator

g. Occupational Health Centre

h. First Aid Boxes

5.7 Emergency Shutting Down Procedure

1. Critical operations will be shut down by the respective technician / operator upon

getting the necessary instruction from the shift in charge. An emergency shut down

can be done after getting approval from Incident Controller / Site Controller.

2. Utility Controls will be shut off by maintenance personnel who will know the

location and operation of main controls for gas, solvent and electrical supply leading

into the building.

3. An emergency shutdown of computers should be accomplished in the event of a

severe electrical storm. If time permits, exit the program and shut off the computer

power supply.

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5.8 Control Room

Control Room also termed as Emergency Control Centre (ECC) is a place from which all

the decisions with regard to actions for control of emergency, rescue and medical

treatment are made. Security office is considered as emergency control centre. It contains

the following facilities.

a. Communication equipment

b. Copies of emergency management plan

c. Emergency escape route map

d. List of emergency contact numbers

e. Emergency light

f. Location of emergency supplies like PPEs / emergency equipments, layout

of fire fighting system, assembly point etc.

g. Emergency organization team details

5.9 Alert Action Plan during Working &Non Working Hours

5.9.1 Alert Action Plan during Working Hours

It can be divided as follows

a. Detection

b. Decision

c. Annunciation

d. Reaction

e. Recovery and Return to normal activities

a) Detection

The detection of any mishap like fire, explosion or toxic release is identified by

either sensors or by any person working in the plant to activate alarm system.

b) Decision

The Department Head / Shift in-charge (Incident Controller) has to assess the

size and nature of emergency and to decide whether it is a minor or major

emergency and then to inform Site Controller immediately.

c) Annunciation

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Site Controller will get complete information of the incident, assess the incident

and if require pass an order to security to wail Emergency Siren through which

every Department will come to know about the emergency, then accordingly

they will plan to evacuate from their respective Departments.

Emergency Siren pattern,

This alarm will blow in the high pitch and low pitch level with interval of 15 sec

between two blows. The mechanism will be in the form of waves of high and

low frequency for 3 minutes.

d) Reaction

After hearing the emergency siren, all should stop their activities in a safe

manner.

Except Emergency Organization Team members, all should come to safe

assemble area and stay there for head count and for further instruction of Site

Controller.

Emergency Organization Team members should act as per their pre- determined

responsibility to;

i. To localize the emergency and if possible to eliminate it

ii. Minimize the effects of accident on people and property

e) Recovery and return to normal activities

Once Emergency is mitigated, normalcy is restored; head count is matched, then

Site Controller will pass an order to Security to wail All Clear Signal.

All Clear Signal Siren pattern. It is a continuous alarm for one minute.

After hearing the All Clear Signal, all can move to their respective work places

to start their normal activities.

5.9.2 Alert Action Plan during Non-Working Hours

During non working hours, i.e., in holidays, there will be no production activities.

As we are carrying only batch processes, all the equipments (both process and

utility) will be shut down and no chemical storage inside the production areas

during holidays and also ensure the cleaning and good housekeeping.

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All the 365 days Fire Hydrant System and Fire alarm systems are kept in active

mode, to monitor this technical person and security persons will present round the

clock throughout the year to tackle the worst case scenario in case of emergency.

5.10 On Site Emergency Planning

A. Constitution of Teams

a. Fire Fighters / Rescuers

b. First Aiders

c. Maintenance Team

a. Fire Fighters / Rescuers

The fire fighters / rescuers shall attempt to extinguish or control the fire / prevent

further toxic leakage without taking personal risk before the arrival of the fire

brigade / other external agency.

The fire fighters / rescuers shall also attempt to save the lives of people who are

unable to ensure their own survival without assistance.

b. First Aiders

The First Aiders shall get ready the first aid equipment, proceed to designated

area and set up First Aid Point in coordination with Site Controller.

c. Maintenance Team

The Maintenance Team shall;

The maintenance team shall go to important controlling areas like Fire Hydrant

Pump House, DG area etc.

B. Define Roles And Responsibilities In Brief

In the event of emergency, nominated individuals / teams are given specific

responsibilities; separate from their day to day activities.

The Emergency Organization Team consist,

a. Site Controller (SC)

b. Incident Controller (IC)

c. Emergency Co-ordinator – HR & Admin

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i. Hospital, Law & Order

ii. Head Count

d. Emergency Co-ordinator Maintenance

e. Emergency Co-ordinator Safety Squad

i. Fire Fighters / Rescuer

ii. First Aider

C.1. Roles and responsibilities of Emergency Organization Team members

a. Site Controller (SC)

Site Controller is a person who has ultimate control over the affairs of the

company during emergencies inside the plant. His responsibilities include;

He should go to the Emergency Control Centre as soon as he is aware of

the emergency and take over the situation.

Get complete information of the incident.

Assess the incident and if require pass an order to security to wail

Emergency Siren.

Remain in ECC and establish the contact with Incident Controller and

guide him about the actions to be taken.

Arrange for additional help as requested by Incident Controller with the

help of Emergency Coordinators.

If required call outside services like fire brigade, medical facility, water

tankers, police etc with the help of Emergency Coordinators.

Guide and control the traffic movements in evacuation.

Establish communication and liaise with agencies like Department of

Factories and Boilers, Pollution Control Board, Police and other

Government Officials.

Inform Incident Controller about missed people if any, after head count

has been done.

To issue authorized statements to the news media.

Once situation is controlled, head count matched then instructs security to

wail ‘All Clear Signal’.

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Rehabilitation of affected areas after the emergency.

b. Incident Controller (IC)

Incident Controller is a person who is responsible for incident control

measures, rescue operations and mitigation of emergency situation on

Coordination with Site Controller. His responsibilities include;

Proceed to the incident spot as information is received.

Assess the size and nature of emergency and communicate the same to

Site Controller and keep in touch with Site Controller till the emergency is

mitigated / controlled.

Start and direct all emergency control operations with the help of

Emergency Coordinator - Safety Squads.

Request Site Controller for additional help like Safety Squads from other

Departments, fire brigades etc.

Direct shut down of the processes / plants and also nearby plants.

Ensure evacuation of all personnel in coordination with Site Controller.

Once emergency is mitigated, normalcy is observed, instruct Site

Controller for the same.

c. Emergency Co-ordinator – HR & Admin

HR & Admin team consist two persons, one person will be stationed at the

Emergency Control Centre during the emergency to handle hospital, fire,

police and other inquiries under instruction of Site Controller and other person

will carry out headcount at assembly point and pass on the absentee

information to the Site Controller.

i. Emergency Co-ordinator Hospital, Law & Order

His responsibilities shall include -

Proceed to the Emergency Control Centre and report to Site

Controller.

Ensure the gates are closed.

With the help of security, control crowd at gate as per instruction

from Site Controller.

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Deploy one guard at main gate with instructions not to allow / send

any personnel, vehicles inside except fire tender and ambulance.

Keep ready the list of important telephone numbers and contact

numbers of police and other law and other agencies.

Inform other statutory departments, corporate office as per

instruction from Site Controller.

Inform relatives / contact persons of the injured accordingly.

Get hold of medical management procedure / list, hospital /

telephone numbers, accordingly.

Call the respective medical institute as per the instruction from Site

Controller.

Prepare a sequential report of the incident.

ii. Emergency Co-ordinator Head Count

His responsibilities shall include -

Proceed to the Emergency Control Centre and report to Site

Controller

Ensure carrying Master Attendance Copy.

Proceed to assembly point and collect attendance sheet from

respective department.

Compare the list and look for missing personnel if any.

Inform Site Controller about the same.

d. Emergency Co-ordinator Maintenance

Emergency Co-ordinator Maintenance will take care of emergency control

systems like Fire Hydrant System, DG units etc and also mobilize the tool and

other emergency equipments as per the instruction of Site Controller.

One of the co-ordinator will move to Fire Hydrant pump house and switch

on /off the pump as per the instruction of Site Controller.

One of the co-ordinator will move to Generator room and switch on / off

as per the instruction of Site Controller.

One of the co-ordinator will be available on phone and act as per the

instruction of Site Controller.

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e. Emergency Co-ordinator Safety Squad

Emergency Co-ordinator Safety Squads will fight the emergency to mitigate it

and to protect life, property.

i. Emergency Co-ordinator Fire Fighters / Rescuer

Proceed to the incident spot along with emergency equipments and

report to Incident Controller.

Set up emergency equipment.

Act as per the instruction of Incident Controller.

Make quick assessment of the injured and arrange to shift with the

help of Incident Controller to safer place for first aid.

Send one co-ordinator of the team along with injured.

Search for missed ones and do rescue operation for the needy.

ii. Emergency Co-ordinator First aider

Proceed to Emergency Control Centre along with team and report to

Site Controller.

Set up emergency equipments.

Be ready to receive and to provide first aid to victim and to help the

ambulance staff.

Make quick assessment of the injured and arrange to send victim to

hospital with the coordination of Site Controller.

Send one co-ordinator of the team to hospital along with injured

with medical management procedures.

C.2. Roles and responsibilities of persons other than Emergency Organization Team

members

Do not venture out for help.

Be available in the Department till evacuation is called.

After hearing the Emergency siren, all should stop their work in a safe manner

immediately.

All work permits will be cancelled automatically.

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All should come to Safe Assembly Area (In front of Safety Office).

While coming to Safe Assemble Area,

Do not run, walk brisk.

Do not use lift, use only staircase.

Do not block staircase, use hand rail. Come in a line.

Do not obstruct / block the path to Emergency Organization Team

members.

Do not go back for your belongings.

Do not use telephone except for emergency purpose.

Follow instructions of Site Controller in Safe Assemble Area.

After All Clear Signal, all can go back to their respective places / Departments.

C. Notification of Emergency

The notification of any mishap like fire, explosion or toxic release is identified by either

sensors or by any person working in the plant. If detection by sensors, alarm system will

get activated or if it by a person, he will activate alarm system. As soon as Incident

Controller aware of the emergency, he will rush to incident spot and assess the size and

nature of emergency and communicate the same to Site Controller.

D. Declaration of Emergency

Site Controller will be the person to decide whether the situation warrants evacuation of

the premises or is a localized incident. This individual will be termed as the declarer of

emergency. Immediately the declarer will make arrangements to give information to the

Executive Director.

Once an emergency requiring evacuation has been decided upon by the declarer, the

Emergency will be declared by putting on the Emergency Siren.

E. Evacuation of Personnel

All Safety Squad co-ordinators from the Department where the incident has occurred and

from other Department will reach earliest to the point of incident. All other people

working in the factory will assemble at designated assembly point i.e., in front of Safety

Department after hearing the Emergency Siren.

The Emergency co-ordinators will assist in directing the individuals to the assembly

point.

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F. Accounting of Personnel

The Emergency Co-ordinator HR & Admin, Head Count Person will conduct head count

as per particular days attendance record at the assembly point to account for persons

working inside the factory and also for visitors / vendors present inside the premises.

Information on missing persons will immediately convey to Site Controller.

G. Controlling of Emergency

The Safety Squad member from the affected area and Safety Squad members from other

Departments will attempt to control / mitigate the emergency situation under the

supervision of Incident Controller and instruction of Site Controller.

H. Arrangements for Medical Treatment

Any person injured in the incident and subsequently, will be treated by Emergency

coordinator, First Aider.

First Aid team member will accompany the injured to hospital. In the event of additional

medical help, the injured will be shift to recommended Hospital.

I. Information to the Relatives of the Injured

The relatives of injured will be informed by Emergency Coordinator HR & Admin for

Hospital, Law & Order. The communications to the relatives of injured will be through

telecom or by a messenger. The clear address of availability of the injured person (if

hospitalized) will be communicated to his relatives.

J. Information to the Government Authorities

The Emergency Coordinator HR & Admin for Hospital, Law and Order is the person to

inform and get help from Fire Station, Police and other Government Hospitals in

coordinating with Site Controller.

K. Law & Order

Site Controller will take over and control emergency in coordination with Incident

Controller and other Emergency Coordinators.

The Executive Director will arrange to send information regarding the incident to the

Director of Factories, Government of Karnataka.

L. All Clear Signal

Once Emergency is mitigated, normalcy is restored; head count is matched, then Site

Controller will pass an order to Security to wail All Clear Signal.

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After hearing the All Clear Signal, all can move to their respective work places to start

their normal activities.

5.11 Offsite Emergency Plan

5.11.1 Preamble

An offsite emergency arising out of chemical hazards in one, which has potential to cause serious

damage or loss of life beyond the plant boundary. In addition, Accidents during transportation of

hazardous chemicals by road, rail, pipeline etc. can cause offsite emergencies.

Emergency services such as Police, Fire, Medical etc., need to be prepared to handle such

situations promptly and effectively.

It is mandatory under Rule 16 of the Hazardous Chemical Rules for District authorities to

prepare an off-site emergency plan in respect of clusters of hazardous chemical industries or at

locations where accidents are likely to have an off-site adverse effect.

In order to be in a state of preparedness to respond to the accidents and minimize their adverse

impacts on the offsite population, requires an offsite emergency plan to be prepared by the

District Controller for every District or Industrial Areas as applicable.

5.11.2 Objective

The objective of the present assignment is to prepare an area specific Offsite Emergency Action

Plan for Karnataka which can be practically implemented / activated at a short notice to ensure

minimal impact on life and property due to emergencies arising out of Chemical Accidents or

during Transportation of Hazardous Chemicals in the district.

The plan should be regularly updated when there are changes occurring in the Industrial set up,

Transportation Aspects, Key Manpower and Administrative Changes etc., Regular drills,

Training of key persons, increasing safety awareness etc is extremely important areas that must

be looked into for sound preparedness.

5.11.3 Offsite Emergency Control

As we all know that KIADB industrial area having many industries of large, medium & small

scale.

After the “Bhopal Gas Tragedy” (Methyl Isocyanides- MIC Poisonous and toxic gas release

Accident at Union Carbide, 1984) the Government felt an immediate need to be more conscious

about handling of Hazardous Chemicals.

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Central control room Centre or Offsite Industrial Emergency Control Room “OIECR” should be

established by company. It should work under the Governing Council. The Governing Council

should be headed under the chairmanship by District Collector & Magistrate.

The Governing Council Members are the permanent Ex. Officio Members to manage the affairs

of the Emergency Control Room.

5.11.4 Emergency Instruction to the General Public

The Notification of Emergency

The emergency can be declared by following media to alert or alarm the public;

1. Public address system

2. Blow horns/Bells

3. Sirens / Hooters

4. Telephone message / Fax Messages / Hot lines/ Pager / E-mail / Mobile Phone / Satellite

system

5. Sending messages through a messenger

6. Rushing personally to the Central Control Room or to the nearest Police Department or

Fire Department for declaration of emergency.

7. Raising of Flag for denoting the level of natural calamities

8. Ham Radio

9. By any other source by which information can reach to the public in time.

5.11.5 Category of Alarm Systems

The following alarm system may be considered which will identify the various level of

emergency.

5.11.5.1 First Level Warning (Fire Alarm)

For an accident / incident within the unit

Hooter / Siren – Short, intermittent

5.11.5.2 Second Level Warning

When the District Authority receives information that a toxic or flammable gas has

leaked then the siren has to be sounded in order to facilitate early evacuations

from the unit.

Siren – A wailing short and long intermittent siren notification of emergency.

5.11.5.3 Third Level Warning (All Clear)

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When the District Authority considers that the accident / incident is under control,

emergency is withdrawing and it is safe for re-entry.

Siren – A wailing, long and continues, intermittent siren.

5.11.6 Fire Fighting System

In order to tackle great risk of fire explosion, spillage of hazardous liquid or release of toxic

gases, fire fighting system should be mobilized under chief fire officer. The operational response

will be coordinated from the Central Control Room.

5.11.7 General Instruction to the Public

A major emergency may affect areas outside the works. The surrounding public will be alerted

with public address system by Police or Government Authorities or nearby industrial concerns.

The siren / hooter will blow to indicate arising the emergency situation.

It will be indicated which kind of emergency arised, Start the Radio / TV for further instruction

& act accordingly. So that public will take prompt action to protect them-selves or rush to the

safe shelter as instructed by the authority.

First of all to ascertain which type of emergency arised.

1. Fire

2. Explosion

3. Gas Leakage / Release

4. Collapse of Building, Brusting of Vessel etc.

5. Natural Calamities.

If gas leakage emergency arised, ascertain probability of gas whether flammable, toxic or

poisonous. The following actions are suggested as per prevailing situation: Otherwise follow

the instruction as issued by the authority

5.11.7.1 Flammable Gas :

a. Be calm, don’t get panicky

b. Do not light Cigarette etc

c. Shut down open flame, gas and electrical instruments or any source of ignition

d. Do not move any vehicle in the area

e. Do not go near the incident & don’t allow any others

f. Shut down the windows, doors etc. & seat open ground or terrace.

g. Follow the instruction as directed by the authority

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5.11.7.2 Toxic Poisonous Gas

a. Cover your nose with wet hand kerchief / cloth and breath through it.

b. Come out in open, check the wind direction and move away quickly in perpendicular

direction of wind. (cross wind direction )

c. Immediately go & try to get to a higher elevation, if gas is heavier than air (like chlorine, as

it settles in low lying area)

Follow the instruction and reach safe shelter as instructed notified by Government Authority or

Public authority.

5.11.7.3 General Instruction :

(A) DON’T1. Do not get panicky, be calm

2. Do not approach the site of incident as a spectator

3. Do not approach unnecessarily for information or more enquires

4. Do not allow unnecessarily crowd nearby incident place

5. Do not believe in rumors unnecessarily

(B) DO’S1. Listen radio, TV or Public Addressing System.

2. Emergency will be communicated by public addressing system / TV / Radio or siren (Siren-

code wailing sound for one minute)

3. Follow the instruction & convey to others accordingly

4. On announcement of withdrawal of emergency or clearance Siren, start your routine work

5. On enquiry, deposit your statement as required by authority at the time of investigating the

incident

6. Co-operate, help and assist the person(s) / authority handling the emergency and rescue

operation.

5.11.8 Security & Police

Security, protection of life & property and traffic control & maintenance of law and order should

be taken care by police. During an emergency duties and responsibilities of the police may be:

a) Cordoning of the incident area

b) Warning public about the hazards

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c) Traffic Control

d) Assist fire fighting services

e) Assist first-aid medical teams

f) Assist evacuation and ensure protection of property in evacuated areas.

Different phases of emergency management practices would be as under:

a) Before the Crisis

Proper planning of manpower, transport and communication network to

coordinate possible incident areas and regulation of traffic should be made for

each industry in the area.

b) During the Crisis

The Security Commander of the area will set in motion the relevant contingency

plan to control the operation.

c) After the Crisis

Protect property in the evacuated area.

d) Media

The Control Room should release up-to-date information to the media to the

people.

risk assessment report -...

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